Method and apparatus for ophthalmic devices including gradient-indexed liquid crystal layers and shaped dielectric layers

ABSTRACT

This invention discloses methods and apparatus for providing a variable optic insert into an ophthalmic lens. A liquid crystal layer may be used to provide a variable optic function and in some embodiments, an alignment layer for the liquid crystal layer may be patterned in a radially dependent manner. The patterning may allow for the index of refraction of the optic device to vary in a gradient indexed or GRIN manner. At least a first layer of dielectric material that may vary in thickness at least across the optic zone of the device may aid in defining an electric field across the liquid crystal layer. An energy source is capable of powering the variable optic insert included within the ophthalmic lens. In some embodiments, an ophthalmic lens is cast-molded from a silicone hydrogel. The various ophthalmic lens entities may include electroactive liquid crystal layers to electrically control optical characteristics.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation in Part application of U.S.non-provisional patent application Ser. No. 14/469,922, filed Aug. 27,2014 and entitled “Method and Apparatus for Ophthalmic Devices IncludingGradient-Indexed and Shaped Liquid Crystal Layers”, the contents ofwhich are relied upon and incorporated by reference. This applicationalso claims priority to Provisional Application No. 61/878,723 filedSep. 17, 2013.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention describes an ophthalmic lens device with a variable opticcapability and, more specifically, in some embodiments, the fabricationof an ophthalmic lens with a variable optic insert utilizing liquidcrystal elements.

2. Discussion of the Related Art

Traditionally an ophthalmic lens, such as a contact lens or anintraocular lens provided a predetermined optical quality. A contactlens, for example, may provide one or more of the following: visioncorrecting functionality; cosmetic enhancement; and therapeutic effects,but only a set of vision correction functions. Each function is providedby a physical characteristic of the lens. Basically, a designincorporating a refractive quality into a lens provides visioncorrective functionality. A pigment incorporated into the lens mayprovide a cosmetic enhancement. An active agent incorporated into a lensmay provide a therapeutic functionality.

To date optical quality in an ophthalmic lens has been designed into thephysical characteristic of the lens. Generally, an optical design hasbeen determined and then imparted into the lens during fabrication ofthe lens, such as, for example through cast molding, or lathing. Theoptical qualities of the lens have remained static once the lens hasbeen formed. However, wearers may at times find it beneficial to havemore than one focal power available to them in order to provide sightaccommodation. Unlike spectacle wearers, who may change spectacles tochange an optical correction, contact wearers or those with intraocularlenses have not been able to change the optical characteristics of theirvision correction without significant effort or the complementing ofspectacles with contact lenses or intraocular lenses.

SUMMARY OF THE INVENTION

Accordingly, the present disclosure includes innovations relating to avariable optic insert with liquid crystal elements that may be energizedand incorporated into an ophthalmic device, which is capable of changingthe optical quality of the device. Examples of such ophthalmic devicesmay include a contact lens or an intraocular lens. In addition, methodsand apparatus for forming an ophthalmic lens with a variable opticinsert with liquid crystal elements are presented. Some embodiments mayalso include a cast-molded silicone hydrogel contact lens with a rigidor formable energized insert, which additionally includes a variableoptic portion, wherein the insert is included within the ophthalmic lensin a biocompatible fashion.

The present disclosure therefore includes disclosure of an ophthalmiclens with a variable optic insert, apparatus for forming an ophthalmiclens with a variable optic insert, and methods for manufacturing thesame. An energy source may be deposited or assembled onto a variableoptic insert and the insert may be placed in proximity to one, or bothof, a first mold part and a second mold part. A composition comprising areactive monomer mixture (hereafter referred to as a reactive monomermixture) is placed between the first mold part and the second mold part.The first mold part is positioned proximate to the second mold partthereby forming a lens cavity with the energized media insert and atleast some of the reactive monomer mixture in the lens cavity; thereactive monomer mixture is exposed to actinic radiation to form anophthalmic lens. Lenses are formed via the control of actinic radiationto which the reactive monomer mixture is exposed. In some embodiments,an ophthalmic lens skirt or an insert-encapsulating layer comprisesstandard hydrogel ophthalmic lens formulations. Exemplary materials withcharacteristics that may provide an acceptable match to numerous insertmaterials may include, for example, the Narafilcon family (includingNarafilcon A and Narafilcon B), the Etafilcon family (includingEtafilcon A), Galyfilcon A and Senofilcon A.

The methods of forming the variable optic insert with liquid crystalelements and the resulting inserts are important aspects of variousexamples of the invention. In some examples, the liquid crystal may belocated between two alignment layers, which may set the restingorientation for the liquid crystal. In some examples the alignmentlayers may be patterned in various manners. The patterning of thealignment layers may be performed such that the alignment of themolecules in the alignment layer interacts with liquid crystal moleculesto form a smoothly varying pattern from a first orientation in thecenter of the lens to a second orientation at or near the edge of thelens. The smoothly varying pattern may be classified as a gradientpattern and since the orientation of liquid crystal molecules may affectthe effective index of refraction of the layer the smoothly varyingpattern may also be classified as forming a gradient indexed pattern.Those two alignment layers may be in electrical communication with anenergy source through electrodes deposited on substrate layers thatcontain the variable optic portion. The electrodes may be energizedthrough an intermediate interconnect to an energy source or directlythrough components embedded in the insert. In some examples a dielectriclayer may be formed proximate to the electrodes, wherein the dielectriclayer varies in thickness at least within the portion within the opticalzone of the resulting device.

The energization of the electrode layers may cause a shift in the liquidcrystal from a resting orientation which may be patterned in a gradientindexed pattern to an energized orientation. In embodiments that operatewith two levels of energization, on or off, the liquid crystal may onlyhave one energized orientation. In other alternative embodiments, whereenergization occurs along a scale of energy levels, the liquid crystalmay have multiple energized orientations. Still further embodiments mayderive where the energization process may cause a switch betweendifferent states through an energization pulse. The energization of theelectrodes where there is a dielectric layer proximate to the electrodesmay cause a shaped variation in electric field across the layercomprising liquid crystal. The shaping of the variation in electricfield may be programmed by controlling the thickness variation of thedielectric thickness and the shaping may all of a variation in electricfield that allows for a particular potential applied to the electrodesto establish a focusing condition at a voltage intermediate between noapplied electric field and a large applied electric field that fullyaligns neighboring layers of liquid crystal along the electric filed.

The resulting alignment and orientation of the molecules may affectlight that passes through the liquid crystal layer thereby causing thevariation in the variable optic insert. For example, the alignment andorientation may act with refractive characteristics upon the incidentlight. Additionally, the effect may include an alteration of thepolarization of the light. Some embodiments may include a variable opticinsert wherein energization alters a focal characteristic of the lens.

In some embodiments, the liquid crystal layer may be formed in a mannerwherein a polymerizable mixture comprising liquid crystal molecules iscaused to polymerize. The monomer(s) used to form the polymer matrix mayitself contain attached liquid crystal portions. By controlling thepolymerization and including liquid crystal molecules unattached to themonomer compounds a matrix of cross-linked polymer regions may be formedthat encompass regions where the individual liquid crystal molecules arelocated. In some terminology such a combination of cross-linkedpolymerized molecules with interstitial included liquid crystalmolecules may be call a network arrangement. Alignment layers may guidealignment of the liquid crystal molecules which are attached to monomersuch that the network of polymerized material is aligned to the guidingalignment layers. In some examples, there may be a smoothly varyingpattern formed by various manners into the alignment layers which maythen cause the liquid crystal molecules or networks of liquid crystalmaterial to form gradient indexed patterns. The attached liquid crystalmolecules are locked into an orientation during the polymerization,however the interstitially located liquid crystal molecules may be freeto orient in space. When no external influence is present, the freeliquid crystal molecules will have their alignment influenced by thematrix of aligned liquid crystal molecules.

Accordingly, in some embodiments an ophthalmic device may be formed bythe incorporation of a variable optic insert comprising liquid crystalmolecules within an ophthalmic device. The variable insert may compriseat least a portion which may be located in the optic zone of theophthalmic device. The variable insert may comprise a front insert pieceand a back insert piece. In some examples, the liquid crystal moleculesmay be aligned into a pattern wherein the index of refraction across aleast a first portion of the optic insert may vary with a radialdependence. The radial dependence may have a primarily parabolicdependence on the radial distance and in some examples, the radialdependence may have parabolic and higher order parametric dependence onthe radial distance from a center of the optic device.

The front and back insert pieces may have either or both of theirsurfaces curved in various manners, and in some embodiments the radiusof curvature of a back surface on the front insert piece may bedifferent from the radius of curvature of the front surface of the backinsert piece. In an alternative manner of description, in someembodiments, the front insert piece may have a surface with a firstcurvature, and the back insert piece may have a second surface with asecond curvature. In some embodiments the first curvature may bedifferent from the second curvature. An energy source may be includedinto the lens and into the insert, and in some embodiments the energysource may be located wherein at least a portion of the energy source isin the non-optic zone of the device. A dielectric layer may be locatedproximate to at least one of the curved front insert piece and thecurved back insert piece, wherein the dielectric layer varies inthickness at least within the portion within the optical zone.

In some embodiments the gradient indexed layer comprising liquid crystalmaterial may be capable of causing an optical effect supplementary tothe effect of the different radii of insert surfaces.

In some embodiments the ophthalmic device may be a contact lens.

In some embodiments the insert of the ophthalmic device may compriseelectrodes made of various materials, including transparent materialssuch as indium tin oxide (ITO) as a non-limiting example. A firstelectrode may be located proximate to a back surface of a front curvepiece, and a second electrode may be located proximate to a frontsurface of a back curve piece. When an electric potential is appliedacross the first and second electrodes, an electric field may beestablished across a liquid crystal layer located between theelectrodes. The application of an electric field across the liquidcrystal layer may cause free liquid crystal molecules within the layerto physically align with the electric field. In some embodiments, thefree liquid crystal molecules may be located in interstitial regionswithin a network of polymer and in some embodiments the polymer backbonemay contain chemically bound liquid crystal molecules which may bealigned during polymerization by alignment layers. When the liquidcrystal molecules align with the electric field, the alignment may causea change in the optical characteristics that a light ray may perceive asit traverses the layer containing liquid crystal molecules. Anon-limiting example may be that the index of refraction may be alteredby the change in alignment. In some embodiments, the change in opticalcharacteristics may result in a change in focal characteristics of thelens which contains the layer containing liquid crystal molecules.

In some embodiments, the ophthalmic devices as described may include aprocessor.

In some embodiments, the ophthalmic devices as described may include anelectrical circuit. The electrical circuit may control or directelectric current to flow within the ophthalmic device. The electricalcircuit may control electrical current to flow from an energy source tothe first and second electrode elements.

The insert device may comprise more than a front insert piece and a backinsert piece in some embodiments. An intermediate piece or pieces may belocated between the front insert piece and the back insert piece. In anexample, a liquid crystal containing layer may be located between thefront insert piece and the intermediate piece. The variable insert maycomprise at least a portion which may be located in the optic zone ofthe ophthalmic device. The front, intermediate and back insert piece mayhave either or both of their surfaces curved in various manners, and insome embodiments the radius of curvature of a back surface on the frontinsert piece may be different from the radius of curvature of the frontsurface of the intermediate insert piece. A dielectric layer may belocated proximate to at least one of the curved front insert piece thecurved intermediate insert piece and the curved back insert piece,wherein the dielectric layer varies in thickness at least within theportion within the optical zone. An energy source may be included intothe lens and into the insert, and in some embodiments the energy sourcemay be located wherein at least a portion of the energy source is in thenon-optic zone of the device.

The insert with a front insert piece, a back insert piece and at least afirst intermediate insert piece may comprise at least a first liquidcrystal molecule, and the liquid crystal molecule or molecules may alsobe found in polymer networked regions of interstitially located liquidcrystal molecules. In some examples, there may be a smoothly varyingpattern formed by various manners into alignment layers which may thencause the liquid crystal molecules or networks of liquid crystalmaterial to form gradient indexed patterns. In some embodiments ofgradient indexed patterns, the liquid crystal molecules may be alignedinto a pattern wherein the index of refraction across at least a firstportion of the optic insert may vary with a radial dependence. Theradial dependence may have a primarily parabolic dependence on theradial distance or a radial dimension, and in some examples, the radialdependence may have parabolic and higher order parametric dependence onthe radial distance or radial dimension from a center of the opticdevice.

In some embodiments with a front insert piece, a back insert piece andat least a first intermediate insert piece the ophthalmic device may bea contact lens.

In some embodiments the insert of the ophthalmic device with a frontinsert piece, a back insert piece and at least a first intermediateinsert piece may comprise electrodes made of various materials,including transparent materials such as ITO as a non-limiting example. Afirst electrode may be located proximate to a back surface of a frontcurve piece, and a second electrode may be located proximate to a frontsurface of an intermediate piece. When an electric potential is appliedacross the first and second electrodes, an electric field may beestablished across a liquid crystal layer located between theelectrodes. The application of an electric field across the liquidcrystal layer may cause liquid crystal molecules within the layer tophysically align with the electric field. In some embodiments, theliquid crystal molecules may be located in polymer networked regions ofinterstitially located liquid crystal material. When the liquid crystalmolecules align with the electric filed, the alignment may cause achange in the optical characteristics that a light ray may perceive asit traverses the layer containing liquid crystal molecules. Anon-limiting example may be that the index of refraction may be alteredby the change in alignment. In some embodiments, the change in opticalcharacteristics may result in a change in focal characteristics of thelens which contains the layer containing liquid crystal molecules.

In some embodiments the intermediate piece may comprise multiple piecesthat are joined together.

In some embodiments where the insert device may be comprised of a frontinsert piece, a back insert piece and an intermediate piece or pieces, aliquid crystal containing layer may be located between the front insertpiece and the intermediate piece or between the intermediate piece andthe back insert piece. In addition, a polarizing element may be locatedwithin the variable insert device as well. The variable insert maycomprise at least a portion which may be located in the optic zone ofthe ophthalmic device. The front, intermediate and back insert piecesmay have either or both of their surfaces curved in various manners, andin some embodiments the radius of curvature of a back surface on thefront insert piece may be different from the radius of curvature of thefront surface of the intermediate insert piece. An energy source may beincluded into the lens and into the insert and in some embodiments theenergy source may be located wherein at least a portion of the energysource is in the non-optic zone of the device.

In some embodiments it may be possible to reference surfaces within thevariable optic insert rather than pieces. In some embodiments, anophthalmic lens device may be formed where a variable optic insert maybe positioned within the ophthalmic lens device where at least a portionof the variable optic insert may be positioned in the optical zone ofthe lens device. These embodiments may include a curved front surfaceand a curved back surface. In some embodiments the front surface and theback surface may be configured to form at least a first chamber. Theophthalmic lens device may also include an energy source embedded in theinsert in at least a region comprising a non-optical zone. In someexamples, a dielectric layer may be placed proximate to at least one ofthe curved front surface and the curved back surface, wherein thedielectric layer varies in thickness at least within the portion withinthe optical zone;

The ophthalmic lens device may also include a layer containing liquidcrystal material positioned within the chamber, wherein the layerincludes regions of liquid crystal material aligned in a pattern whereinthe index of refraction across at least a first portion of the variableoptic insert varies with a radial dependence.

In some embodiments a contact lens device may be formed where a variableoptic insert may be positioned within the ophthalmic lens device whereat least a portion of the variable optic insert may be positioned in theoptical zone of the lens device. These embodiments may include a curvedfront surface and a curved back surface. In some embodiments the frontsurface and the back surface may be configured to form at least a firstchamber. The contact lens device may also include a layer containingliquid crystal material positioned within the chamber, wherein the layerincludes regions of liquid crystal material aligned in a pattern whereinthe index of refraction across at least a first portion of the variableoptic insert varies with a radial dependence. The contact lens devicemay also include a dielectric layer proximate to at least one of thecurved front surface and the curved back surface, wherein the dielectriclayer varies in thickness at least within the portion within the opticalzone

In some embodiments a contact lens device may be formed where a variableoptic insert may be positioned within the ophthalmic lens device whereat least a portion of the variable optic insert may be positioned in theoptical zone of the lens device. The contact lens device may alsoinclude a layer containing liquid crystal material positioned within thechamber, wherein the layer may include regions of liquid crystalmaterial aligned in a pattern wherein the index of refraction across atleast a first portion of the variable optic insert varies with a radialdependence, and wherein at least a first surface of the layer may becurved.

In some embodiments an ophthalmic lens device may be formed where avariable optic insert may be positioned within the ophthalmic lensdevice where at least a portion of the variable optic insert may bepositioned in the optical zone of the lens device. These embodiments mayinclude a curved front surface and a curved back surface. In someembodiments a first curved front surface and a first curved back surfacemay be configured to form at least a first chamber. A second curvedfront surface and a second curved back surface may be configured to format least a second chamber. The ophthalmic lens device may also include alayer containing liquid crystal material positioned within the firstchamber, wherein the layer includes regions of liquid crystal materialaligned in a pattern wherein the index of refraction across at least afirst portion of the variable optic insert varies with a radialdependence. The ophthalmic device may comprise a dielectric layerproximate to at least one of the first curved front surface and thefirst curved back surface or the second curved front surface and thesecond curved back surface wherein the dielectric layer varies inthickness at least within the portion within the optical zone. Theophthalmic lens device may also include an energy source embedded in theinsert in at least a region comprising a non-optical zone. In someembodiments the ophthalmic lens may be a contact lens.

In some embodiments a contact lens device may be formed where a variableoptic insert may be positioned within the ophthalmic lens device whereat least a portion of the variable optic insert may be positioned in theoptical zone of the lens device. The contact lens may include a curvedfirst front surface and a curved first back surface wherein the firstfront surface and the first back surface are configured to form at leasta first chamber. The contact lens may also include a first layer ofelectrode material proximate to the back surface of the curved firstfront surface. The contact lens may also comprise a second layer ofelectrode material proximate to the front surface of the first backcurve piece. The contact lens may also include a first layer containingliquid crystal material positioned within the first chamber, wherein thefirst layer includes regions of liquid crystal material aligned in apattern wherein the index of refraction across at least a first portionof the variable optic insert varies with a radial dependence and whereinthe first layer of liquid crystal material varies its index ofrefraction affecting a ray of light traversing the first layer of liquidcrystal material when an electric potential is applied across the firstlayer of electrode material and the second layer of electrode material.The contact lens device may additionally include a curved second frontsurface and a curved second back surface wherein the second frontsurface and the second back surface are configured to form at least asecond chamber. The contact lens device may also comprise a third layerof electrode material proximate to the back surface of the curved secondfront surface, and a fourth layer of electrode material proximate to thefront surface of the second back curve piece. A second layer containingliquid crystal material positioned within the second chamber may also beincluded wherein the second layer is layer includes regions of liquidcrystal material aligned in a pattern wherein the index of refractionacross at least a first portion of the variable optic insert varies witha radial dependence, and wherein the second layer of liquid crystalmaterial varies its index of refraction affecting a ray of lighttraversing the first layer of liquid crystal material when an electricpotential is applied across the third layer of electrode material andthe forth layer of electrode material. The ophthalmic device maycomprise a dielectric layer proximate to at least one of the firstcurved front surface and the first curved back surface or the secondcurved front surface and the second curved back surface wherein thedielectric layer varies in thickness at least within the portion withinthe optical zone. The contact lens may also include an energy sourceembedded in the insert in at least a region comprising a non-opticalzone. The contact lens may also include an electrical circuit comprisinga processor, wherein the electrical circuit controls the flow ofelectrical energy from the energy source to one or more of the first,second, third or fourth electrode layers. And, the contact lens'variable optic insert may also alter a focal characteristic of theophthalmic lens.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will beapparent from the following, more particular description of preferredembodiments of the invention, as illustrated in the accompanyingdrawings.

FIG. 1 illustrates exemplary mold assembly apparatus components that maybe useful in implementing some embodiments of the present disclosure.

FIGS. 2A and 2B illustrate an exemplary energized ophthalmic lens with avariable optic insert embodiment.

FIG. 3A illustrates a cross sectional view of a variable optic insertwhere the front and back curve pieces of the variable optic insert mayhave different curvature and wherein the variable optic portion may becomprised of liquid crystal.

FIG. 3B illustrates a cross sectional view of an ophthalmic lens deviceembodiment with a variable optic insert wherein the variable opticportion may be comprised of polymer networked regions of interstitiallylocated liquid crystal.

FIGS. 4A and 4B illustrate an exemplary gradient indexed pattern in aflattened embodiment that may relate and explain the relevance tovarious embodiments with three dimensional shape.

FIGS. 4C, 4D and 4E illustrate exemplary depictions of the influence ofalignment layers upon liquid crystal molecules and the formation ofpatterns in exemplary manners.

FIG. 4F illustrates exemplary models for the effect of gradient indexpatterning of liquid crystal layers and the resulting focalcharacteristics that may be modeled.

FIG. 5A illustrates an example of a variable optic insert wherein thevariable optic portion may be comprised of gradient indexed regions ofliquid crystal molecules between shaped insert pieces.

FIG. 5B illustrates an example of a variable optic insert wherein thevariable optic portion may be comprised of gradient indexed regions ofnetworked polymer liquid crystal molecules with interstitial liquidcrystal molecules. The liquid crystal containing layer is illustratedbetween shaped insert pieces.

FIG. 5C illustrates a closeup of an example of a variable optic insertwherein the variable optic portion may be comprised of gradient indexedregions of liquid crystal molecules between shaped insert pieces andwherein there is no imposed electric field across the layer and thus maybe in a resting orientation

FIG. 5D illustrates a closeup of an example of a variable optic insertwherein the variable optic portion may be comprised of gradient indexedregions of liquid crystal molecules between shaped insert pieces andwherein there is an imposed electric field across the layer and thus maybe in an energized orientation

FIG. 6 illustrates an alternative embodiment of a variable optic lenscomprising an insert wherein the variable optic portions may becomprised of gradient indexed regions of liquid crystal moleculesbetween shaped insert pieces.

FIG. 7 illustrates method steps for forming an ophthalmic lens with avariable optic insert which may be comprised of gradient indexed regionsof liquid crystal molecules between shaped insert pieces.

FIG. 8 illustrates an example of apparatus components for placing avariable optic insert comprised of gradient indexed regions of liquidcrystal molecules between shaped insert pieces into an ophthalmic lensmold part.

FIG. 9 illustrates a processor that may be used to implement someembodiments of the present disclosure.

FIG. 10A—illustrates cross sectional view of a variable optic insertwhere the front and back curve pieces of the variable optic insert mayhave dielectric layers that vary across the variable optic portion.

FIG. 10B—illustrates cross sectional view of a variable optic insertwhere the front and back curve pieces of the variable optic insert mayhave dielectric layers that vary across the variable optic portion.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure includes methods and apparatus for manufacturingan ophthalmic lens with a variable optic insert wherein the variableoptic portion is comprised of a liquid crystal or a composite materialwhich itself includes liquid crystal constituents. In addition, thepresent disclosure includes an ophthalmic lens with a variable opticinsert comprised of liquid crystal incorporated into the ophthalmiclens.

According to the present disclosure, an ophthalmic lens is formed withan embedded insert and an energy source, such as an electrochemical cellor battery as the storage means for the Energy. In some examples, thematerials comprising the energy source may be encapsulated and isolatedfrom an environment into which an ophthalmic lens is placed. In someexamples the energy source may include an electrochemical cell chemistrywhich may be used in a primary or rechargeable configuration.

A wearer-controlled adjustment device may be used to vary the opticportion. The adjustment device may include, for example, an electronicdevice or passive device for increasing or decreasing a voltage outputor engaging and disengaging the energy source. Some examples may alsoinclude an automated adjustment device to change the variable opticportion via an automated apparatus according to a measured parameter ora wearer input. Wearer input may include, for example, a switchcontrolled by wireless apparatus. Wireless may include, for example,radio frequency control, magnetic switching, patterned emanations oflight, and inductance switching. In other examples activation may occurin response to a biological function or in response to a measurement ofa sensing element within the ophthalmic lens. Other examples may resultfrom the activation being triggered by a change in ambient lightingconditions as a non-limiting example.

Variation in optic power may occur when electric fields, created by theenergization of electrodes, causes realignment within the liquid crystallayer thereby shifting the molecules from the resting orientation to anenergized orientation. In other alternative examples, different effectscaused by the alteration of liquid crystal layers by energization ofelectrodes may be exploited such as, for example, changing of the lightpolarization state, particularly, polarization rotation.

In some examples with liquid crystal layers, there may be elements inthe non-optical zone portion of the ophthalmic lens that may beenergized, whereas other examples may not require energization. In theexamples without energization, the liquid crystal may be passivelyvariable based on some exterior factor, for example, ambienttemperature, or ambient light.

A liquid crystal lens may provide an electrically variable index ofrefraction to polarized light incident upon its body. A combination oftwo lenses where the optical axis orientation is rotated in the secondlens relative to the first lens allows for a lens element that may beable to vary the index of refraction to ambient non-polarized light.

By combining electrically active liquid crystal layers with electrodes,a physical entity may derive that may be controlled by applying anelectrical field across the electrodes. If there is a dielectric layerthat is present on the periphery of the liquid crystal layer, then thefield across the dielectric layer and the field across the liquidcrystal layer may combine into the field across the electrodes. In athree-dimensional shape the nature of the combination of the fieldsacross the layers may be estimated based on electrodynamics principalsand the geometry of the dielectric layer and the liquid crystal layer.If the effective electrical thickness of the dielectric layer is made ina non-uniform manner then the effect of a field across the electrodesmay be “shaped” by the effective shape of the dielectric and createdimensionally shaped changes in refractive index in the liquid crystallayers. In some examples, such shaping may result in lenses that havethe ability to adopt variable focal characteristics.

An alternative example may derive when the physical lens elements thatcontain the liquid crystal layers are shaped themselves to havedifferent focal characteristics. The electrically variable index ofrefraction of a liquid crystal layer may then be used to introducechanges in the focal characteristics of the lens based on theapplication of an electric field across the liquid crystal layer throughthe use of electrodes. The index of refraction of a liquid crystal layermay be referred to as an effective index of refraction, and it may bepossible to consider each treatment relating to an index of refractionas equivalently referring to an effective index of refraction. Theeffective index of refraction may come, for example, from thesuperposition of multiple regions with different indices of refraction.In some examples, the effective aspect may be an average of the variousregional contributions, while in other examples the effective aspect maybe a superposition of the regional or molecular effects upon incidentlight. The shape that the front containment surface makes with theliquid crystal layer and the shape that the back containment surfacemakes with the liquid crystal layer may determine, to first order, thefocal characteristics of the system.

In the following sections detailed descriptions of embodiments of theinvention will be given. The description of both preferred andalternative embodiments are examples only, and it is understood that tothose skilled in the art that variations, modifications and alterationsmay be apparent. It is therefore to be understood that said examples donot limit the scope of the underlying invention.

GLOSSARY

In this description and claims directed to the presented invention,various terms may be used for which the following definitions willapply:

Alignment layer: as used herein refers to a layer adjacent to a liquidcrystal layer that influences and aligns the orientation of moleculeswithin the liquid crystal layer. The resulting alignment and orientationof the molecules may affect light that passes through the liquid crystallayer. For example, the alignment and orientation may act withrefractive characteristics upon the incident light. Additionally, theeffect may include alteration of the polarization of the light.

Electrical Communication: as used herein refers to being influenced byan electrical field. In the case of conductive materials, the influencemay result from or in the flow of electrical current. In othermaterials, it may be an electrical potential field that causes aninfluence, such as the tendency to orient permanent and inducedmolecular dipoles along field lines as an example.

Energized: as used herein refers to the state of being able to supplyelectrical current to or to have electrical energy stored within.

Energized orientation: as used herein refers to the orientation of themolecules of a liquid crystal when influenced by an effect of apotential field powered by an energy source. For example, a devicecontaining liquid crystals may have one energized orientation if theenergy source operates as either on or off. In other examples, theenergized orientation may change along a scale affected by the amount ofenergy applied.

Energy: as used herein refers to the capacity of a physical system to dowork. Many uses within this invention may relate to the said capacitybeing able to perform electrical actions in doing work.

Energy source: as used herein refers to device capable of supplyingenergy or placing a biomedical device in an energized state.

Energy Harvesters: as used herein refers to device capable of extractingenergy from the environment and convert it to electrical energy.

Interstices and Interstitial as used herein refer to regions within theboundaries of a polymer networked layer that are unoccupied by portionsof the polymer and may be locations for other atoms or molecules toreside. Typically, herein, a liquid crystal molecule itself mayco-reside in a region within the polymer network and the space that saidliquid crystal therefore occupies may be classified as an interstice.

Intraocular lens: as used herein refers to an ophthalmic lens that isembedded within the eye.

Lens-Forming Mixture or Reactive Mixture or reactive monomer mixture(RMM): as used herein refers to a monomer or prepolymer material thatmay be cured and crosslinked or crosslinked to form an ophthalmic lens.Various embodiments may include lens-forming mixtures with one or moreadditives such as: UV blockers, tints, photoinitiators or catalysts, andother additives one might desire in an ophthalmic lens such as, forexample, contact or intraocular lenses.

Lens-Forming Surface: as used herein refers to a surface that is used tomold a lens. In some embodiments, any such surface may have an opticalquality surface finish, which indicates that it is sufficiently smoothand formed so that a lens surface fashioned by the polymerization of alens-forming mixture in contact with the molding surface is opticallyacceptable. Further, in some examples, the lens-forming surface may havea geometry that is necessary to impart to the lens surface the desiredoptical characteristics, including, for example, spherical, asphericaland cylinder power, wave front aberration correction, and cornealtopography correction.

Liquid Crystal: as used herein refers to a state of matter havingproperties between a conventional liquid and a solid crystal. A liquidcrystal may not be characterized as a solid, but its molecules exhibitsome degree of alignment. As used herein, a liquid crystal is notlimited to a particular phase or structure, but a liquid crystal mayhave a specific resting orientation. The orientation and phases of aliquid crystal may be manipulated by external forces, for example,temperature, magnetism, or electricity, depending on the class of liquidcrystal.

Lithium Ion Cell: as used herein refers to an electrochemical cell whereLithium ions move through the cell to generate electrical energy. Thiselectrochemical cell, typically called a battery, may be reenergized orrecharged in its typical forms.

Media insert or insert: as used herein refers to a formable or rigidsubstrate capable of supporting an energy source within an ophthalmiclens. In some examples, the media insert also includes one or morevariable optic portions.

Mold: as used herein refers to a rigid or semi-rigid object that may beused to form lenses from uncured formulations. Some preferred moldsinclude two mold parts forming a front curve mold part and a back curvemold part.

Ophthalmic Lens or Lens: as used herein refers to any ophthalmic devicethat resides in or on the eye. These devices may provide opticalcorrection or modification, or may be cosmetic. For example, the term“lens” may refer to a contact lens, intraocular lens, overlay lens,ocular insert, optical insert, or other similar device through whichvision is corrected or modified, or through which eye physiology iscosmetically enhanced (e.g. iris color) without impeding vision. In someexamples, the preferred lenses of the invention are soft contact lenseswhich are made from silicone elastomers or hydrogels, which include, forexample, silicone hydrogels and fluorohydrogels.

Optical zone: as used herein refers to an area of an ophthalmic lensthrough which a wearer of the ophthalmic lens sees.

Power: as used herein refers to work done or energy transferred per unitof time.

Rechargeable or Reenergizable: as used herein refers to a capability ofbeing restored to a state with higher capacity to do work. Many useswithin the present disclosure may relate to the capability of beingrestored with the ability to flow electrical current at a certain ratefor certain, reestablished time period.

Reenergize or Recharge: as used herein refers to the restoration of anenergy source to a state with higher capacity to do work. Many useswithin the present disclosure may relate to restoring a device to thecapability to flow electrical current at a certain rate for a certain,reestablished time period.

Released from a mold: as used herein refers to a lens is eithercompletely separated from the mold, or is only loosely attached so thatit may be removed with mild agitation or pushed off with a swab.

Resting orientation: as used herein refers to the orientation of themolecules of a liquid crystal device in its resting, non-energizedstate.

Variable optic: as used herein refers to the capacity to change anoptical quality, for example, the optical power of a lens or thepolarizing angle.

Ophthalmic Lenses

Referring to FIG. 1, an apparatus 100 to form ophthalmic devicescomprising sealed and encapsulated inserts is depicted. The apparatusincludes an exemplary front curve mold 102 and a matching back curvemold 101. A variable optic insert 104 and a body 103 of the ophthalmicdevice may be located inside the front curve mold 102 and the back curvemold 101. In some examples, the material of the body 103 may be ahydrogel material, and the variable optic insert 104 may be surroundedon all surfaces by this material.

The variable optic insert 104 may comprise multiple liquid crystallayers 109 and 110. Other examples may include a single liquid crystallayer, some of which are discussed in later sections. The use of theapparatus 100 may create a novel ophthalmic device comprised of acombination of components with numerous sealed regions.

In some examples, a lens with a variable optic insert 104 may include arigid center soft skirt design wherein a central rigid optical elementincluding the liquid crystal layers 109 and 110 is in direct contactwith the atmosphere and the corneal surface on respective anterior andposterior surfaces. The soft skirt of lens material (typically ahydrogel material) is attached to a periphery of the rigid opticalelement, and the rigid optical element may also add energy andfunctionality to the resulting ophthalmic lens.

Referring to FIG. 2A, at 200 a top down and FIG. 2B at 250 a crosssectional depiction of an example of a variable optic insert is shown.In this depiction, an energy source 210 is shown in a periphery portion211 of the variable optic insert 200. The energy source 210 may include,for example, a thin film, rechargeable lithium ion battery or analkaline cell based battery. The energy source 210 may be connected tointerconnect features 214 to allow for interconnection. Additionalinterconnects at 225 and 230 for example may connect the energy source210 to a circuit such as electronic circuit 205. In other examples, aninsert may have interconnect features deposited on its surface.

In some examples, the variable optic insert 200 may include a flexiblesubstrate. This flexible substrate may be formed into a shapeapproximating a typical lens form in a similar manner previouslydiscussed or by other means. However to add additional flexibility, thevariable optic insert 200 may include additional shape features such asradial cuts along its length. There may be multiple electroniccomponents such as that indicated by 205 such as integrated circuits,discrete components, passive components and such devices that may alsobe included.

A variable optic portion 220 is also illustrated. The variable opticportion 220 may be varied on command through the application of acurrent through the variable optic insert which in turn may typicallyvary an electric field established across a liquid crystal layer. Insome examples, the variable optic portion 220 comprises a thin layercomprising liquid crystal between two layers of transparent substrate.There may be numerous manners of electrically activating and controllingthe variable optic component, typically through action of the electroniccircuit 205. The electronic circuit, 205 may receive signals in variousmanners and may also connect to sensing elements which may also be inthe insert such as item 215. In some examples, the variable optic insertmay be encapsulated into a lens skirt 255, which may be comprised ofhydrogel material or other suitable material to form an ophthalmic lens.In these examples the ophthalmic lens may be comprised of the lens skirt255 and an encapsulated variable optic insert 200 which may itselfcomprise layers or regions of liquid crystal material or comprisingliquid crystal material and in some examples the layers may comprisepolymer networked regions of interstitially located liquid crystalmaterial.

A Variable Optic Insert Including Liquid Crystal Elements

Referring to FIG. 3A, item 300, an illustration of the lens effect oftwo differently shaped lens pieces may be found. As mentionedpreviously, a variable optic insert of the inventive art herein may beformed by enclosing an electrode and liquid crystal layer system withintwo differently shaped lens pieces. The electrode and liquid crystallayer system may occupy a space between the lens pieces as illustratedat 350. At 320 a front curve piece may be found and at 310, a rear curvepiece may be found.

In a non-limiting example, the front curve piece 320 may have a concaveshaped surface that interacts with the space 350. The shape may befurther characterized as having a radius of curvature depicted as 330and a focal point 335 in some examples. Other more complicated shapeswith various parametric characteristics may be formed within the scopeof the inventive art; however, for illustration a simple spherical shapemay be depicted.

In a similar and also non-limiting fashion, the back curve piece 310 mayhave a convex shaped surface that interacts with the space 350. Theshape may be further characterized as having a radius of curvaturedepicted as 340 and a focal point 345 in some examples. Other morecomplicated shapes with various parametric characteristics may be formedwithin the scope of the inventive art; however, for illustration asimple spherical shape may be depicted.

To illustrate how the lens of the type as 300 may operate, the materialthat comprises the back curve piece 310 and the front curve piece 320may have a natural index of refraction of a value. Within the space 350the liquid crystal layer may be chosen in a non-limiting example tomatch that value for the index of refraction. Thus when light raystraverse the lens pieces and the space 350, they will not react to thevarious interfaces in a manner that would adjust the focalcharacteristics. In its function, portions of the lens not shown mayactivate an energization of various components that may result in theliquid crystal layer in space 350 assuming a different index ofrefraction to the incident light ray. In a non-limiting example theresulting index of refraction may be lowered. Now, at each materialinterface the path of the light may be modeled to be altered based onthe focal characteristics of the surface and the change of the index ofrefraction.

The model may be based on Snell's law: sin (theta₁)/sin(theta₂)=n₂/n₁.For example, the interface may be formed by front curve piece 320 andspace 350; theta₁ may be the angle that the incident ray makes with asurface normal at the interface. Theta₂ may be the modeled angle thatthe ray makes with a surface normal as it leaves the interface. n₂ mayrepresent the index of refraction of the space 350 and n₁ may representthe index of refraction of the front curve piece 320. When n₁ is notequal to n₂ then the angles theta′ and theta₂ will be different as well.Thus, when the electrically variable index of refraction of the liquidcrystal layer in space 350 is changed, the path that a light ray wouldtake at the interface will change as well.

Referring to FIG. 3B, an ophthalmic lens 360 is shown with an embeddedvariable optic insert 371. The ophthalmic lens 360 may have a frontcurve surface 370 and a back curve surface 372. The insert 371 may havea variable optic portion 373 with a liquid crystal layer 374. In someexamples, the insert 371 may have multiple liquid crystal layers 374 and375. Portions of the insert 371 may overlap with the optical zone of theophthalmic lens 360.

Referring to FIG. 4A, a depiction of a gradient indexing effect isfound. In examples with gradient indexing, alignment layers may be usedto control the orientation of liquid crystal molecules. The control ofthe orientation may itself control regional effective index ofrefraction. Thus, the control of the orientation of the liquid crystalmolecules can form a regionally variable effective index of refractionthat may be characterized as a gradient indexed pattern. In FIG. 4A, anexemplary depiction of the effect may be shown where the variouselements are depicted as flat elements. Although effective optic devicesmay be formed from flat elements, such as may be useful in intraocularlens devices which may form parts of the inventive art herein; there mayalso be numerous embodiments that utilize the gradient indexed effectdepicted but are formed into three dimensional shapes as well. At 410 afront optic piece may be found which may support electrodes 420 andalignment layers 425. The alignment layer 425, may be programmed byvarious means, some examples may be found later in this description. Thealignment layer may have a programed alignment that varies from afeature parallel to the surface of the front optic piece as depicted at440 to a perpendicular orientation as depicted at 430 to orientationsbetween these. The effect of the alignment layers programmed orientationmay be to cause the liquid crystal layer to form a gradient indexedpattern. The liquid crystal molecules may align as well with somemolecules being oriented parallel to the front optic surface such asdepicted at 445 and some molecules oriented perpendicular to the frontoptic surface such as depicted at 435 as well as orientations oreffective orientations in between the two extremes. For liquid crystalmolecules this variation may cause the effective index of refraction tovary or be gradated across the optic zone of the optic device formedwith these layers. There may be a back optic piece in some examples asshown at 405. The back optic piece may have electrode layers 415 andalignment layers 426 as well. In some examples these alignment layersmay be programmed to assume orientations similar to those defined on thefront optic surface.

Referring to FIG. 4B, the effect of an electric field 401, appliedacross the liquid crystal layer 475 may be observed. The electric field401 may be established by the energization of electrodes 415 and 420 insome examples. The effect of portions of the alignment layers withdiffering orientation such as 470 and 480 may be overwhelmed by theeffect of the electric field 401 resulting in the similar orientation ofliquid crystal molecules in alignment with the electric field 401 asdepicted at 475 and 485.

Proceeding to FIG. 5B, 560 examples for gradient indexed liquid crystallenses may be depicted where liquid crystal and polymer compositions maybe employed. In a first example, a mixture of a monomer and a liquidcrystal molecule may be formed with the combination being heated to forman homogenous mixture. Next, the mixture may be applied to a front curveinsert piece 561 and then encapsulated in the lens insert by theaddition of a back curve or intermediate insert piece 567. The insertcontaining the liquid crystal mixture may then be caused to polymerizeunder predetermined conditions forming cross-linked networked regions ofpolymerized material as well as intercalated regions of liquid crystalwithin the interstices of the polymer network. In some examples, actinicradiation may be shone on the mixture to initiate polymerization. Thepresence of patterned alignment layers at 563 and 565 may orient themonomers and liquid crystal molecules 564 prior to and during thepolymerization process to form the radially varying pattern as depicted.In some examples there may be transparent electrodes as may be depictedat 562 and 566.

There may be numerous manners to incorporate liquid crystal moleculesinto the polymerized or gelled regions. Therefore, any method ofcreating polymer networked liquid crystal layers may comprise art withinthe scope of the present disclosure and may be used to create anophthalmic device where a gradient indexed radial profile is formed. Theprevious examples mentioned the use of monomers with attached liquidcrystal portions to create networked layers that create interstitiallocations for unbound liquid crystal molecules. The state of the polymermay be a crystalline form, a semicrystalline form or an amorphous formof polymerized material or in other embodiments may also exist as agelled or semi-gelled form of polymer.

The variable optic portion in FIGS. 5A and 4B may have other aspectsthat may be defined by a similar diversity of materials and structuralrelevance as has been discussed in other sections of this specification.In some examples, a first transparent electrode 420 may be placed on thefirst transparent substrate 410. The first lens surface may be comprisedof a dielectric film, and in some examples, alignment layers which maybe placed upon the first transparent electrodes.

Referring to FIG. 5C, item 570 may represent a portion of a gradientindexed lens comprising liquid crystal aligned in a manner consistentwith a gradient indexed lens. Some variation in the orientation of theliquid crystal molecules is depicted in an exemplary fashion for thevariation of the index of refraction with a radial distance. There maybe a first insert piece 571, and a second insert piece 576 withalignment layers 572 and 575 thereupon. The alignment layers may guidethe free standing orientation of liquid crystal molecules 574 within theliquid crystal layer 573.

The same portion of the gradient index lens comprising liquid crystalshown in reference to FIG. 5C may be found in reference to FIG. 5D. Inthe case depicted in FIG. 5D, an electric field may be imposed acrossthe layer comprising aligned liquid crystal molecules and thus may be inan energized orientation. The electric field is depicted by the fieldvector at 580 and is created by the energization of the electrodelayers. The liquid crystal molecules, for example at 581, are shown toalign with the imposed electric field. In this energized configurationthe gradient indexing is essentially erased as the layer lines up topresent a relatively uniform index of refraction to incident radiation.There may be other optical effects of the lens surfaces and shapes, butby lining up the liquid crystal orientations a different focalcharacteristic will result.

Referring to FIG. 6, an alternative of a variable optic insert 600 thatmay be inserted into an ophthalmic lens is illustrated with two liquidcrystal layers 620 and 640. Each of the aspects of the various layersaround the liquid crystal region may have similar diversity as describedin relation to the variable optic insert 500 in FIG. 5A or 560 in FIG.5B. For exemplary purposes, both the layer at 620 and 640 are depictedto have similar gradient indexed programing; however, it may be possibleto combine a gradient index type lens with another liquid crystalelement in some other examples. In some examples, the combination ofmultiple gradient indexed layers may allow for multiple focalcharacteristics to be defined in a compound manner. By combining a firstliquid crystal based element formed by a first substrate 610, whoseintervening layers in the space around 620 and a second substrate 630may have a first focal characteristic, with a second liquid crystalbased element formed by a second surface on the second substrate 630,the intervening layers in the space around 640 and a third substrate 650with a second focal characteristic, a combination may be formed whichmay allow for an electrically variable focal characteristic of a lens asan example.

At the exemplary variable optic insert 600, a combination of twoelectrically active liquid crystal layers of the various types anddiversity associated with the examples at 500 and 560 may be formedutilizing three substrate layers. In other examples, the device may beformed by the combination of four different substrates. In suchexamples, the intermediate second substrate 630 may be split into twolayers. If the substrates are combined at a later time, a device thatfunctions similarly to variable optic insert 600 may result. Thecombination of four layers may present an example for the manufacturingof the element where similar devices may be constructed around both 620and 640 liquid crystal layers where the processing difference may relateto the portion of steps that define alignment features for the liquidcrystal element.

Materials

Microinjection molding embodiments may include, for example, apoly(4-methylpent-1-ene) copolymer resin are used to form lenses with adiameter of between about 6 mm to 10 mm and a front surface radius ofbetween about 6 mm and 10 mm and a rear surface radius of between about6 mm and 10 mm and a center thickness of between about 0.050 mm and 1.0mm. Some examples include an insert with diameter of about 8.9 mm and afront surface radius of about 7.9 mm and a rear surface radius of about7.8 mm and a center thickness of about 0.200 mm and an edge thickness ofabout 0.050 mm.

The variable optic insert 104 illustrated in FIG. 1 may be placed in amold part 101 and 102 utilized to form an ophthalmic lens. Mold part 101and 102 material may include, for example, a polyolefin of one or moreof: polypropylene, polystyrene, polyethylene, polymethyl methacrylate,and modified polyolefins. Other molds may include a ceramic or metallicmaterial.

A preferred alicyclic co-polymer contains two different alicyclicpolymers. Various grades of alicyclic co-polymers may have glasstransition temperatures ranging from 105° C. to 160° C.

In some examples, the molds of the present disclosure may containpolymers such as polypropylene, polyethylene, polystyrene, polymethylmethacrylate, modified polyolefins containing an alicyclic moiety in themain chain and cyclic polyolefins. This blend may be used on either orboth mold halves, where it is preferred that this blend is used on theback curve and the front curve consists of the alicyclic co-polymers.

In some preferred methods of making molds according to the presentdisclosure, injection molding is utilized according to known techniques,however, examples may also include molds fashioned by other techniquesincluding, for example: lathing, diamond turning, or laser cutting.

Typically, lenses are formed on at least one surface of both mold parts101 and 102. However, in some examples, one surface of a lens may beformed from a mold part 101 or 102 and another surface of a lens may beformed using a lathing method, or other methods.

In some examples, a preferred lens material includes a siliconecontaining component. A “silicone-containing component” is one thatcontains at least one [—Si—O—] unit in a monomer, macromer orprepolymer. Preferably, the total Si and attached O are present in thesilicone-containing component in an amount greater than about 20 weightpercent, and more preferably greater than 30 weight percent of the totalmolecular weight of the silicone-containing component. Usefulsilicone-containing components preferably comprise polymerizablefunctional groups such as acrylate, methacrylate, acrylamide,methacrylamide, vinyl, N-vinyl lactam, N-vinylamide, and styrylfunctional groups.

In some examples, the ophthalmic lens skirt, also called aninsert-encapsulating layer, that surrounds the insert may be comprisedof standard hydrogel ophthalmic lens formulations. Exemplary materialswith characteristics that may provide an acceptable match to numerousinsert materials may include, the Narafilcon family (includingNarafilcon A and Narafilcon B), and the Etafilcon family (includingEtafilcon A). A more technically inclusive discussion follows on thenature of materials consistent with the art herein. One ordinarilyskilled in the art may recognize that other material other than thosediscussed may also form an acceptable enclosure or partial enclosure ofthe sealed and encapsulated inserts and should be considered consistentand included within the scope of the claims.

Suitable silicone containing components include compounds of Formula I

where

R¹ is independently selected from monovalent reactive groups, monovalentalkyl groups, or monovalent aryl groups, any of the foregoing which mayfurther comprise functionality selected from hydroxy, amino, oxa,carboxy, alkyl carboxy, alkoxy, amido, carbamate, carbonate, halogen orcombinations thereof; and monovalent siloxane chains comprising 1-100Si—O repeat units which may further comprise functionality selected fromalkyl, hydroxy, amino, oxa, carboxy, alkyl carboxy, alkoxy, amido,carbamate, halogen or combinations thereof;

where b=0 to 500, where it is understood that when b is other than 0, bis a distribution having a mode equal to a stated value;

wherein at least one R¹ comprises a monovalent reactive group, and insome embodiments between one and 3 R¹ comprise monovalent reactivegroups.

As used herein “monovalent reactive groups” are groups that may undergofree radical and/or cationic polymerization. Non-limiting examples offree radical reactive groups include (meth)acrylates, styryls, vinyls,vinyl ethers, C₁₋₆alkyl(meth)acrylates, (meth)acrylamides,C₁₋₆alkyl(meth)acrylamides, N-vinyllactams, N-vinylamides,C₂₋₁₂alkenyls, C₂₋₁₂alkenylphenyls, C₂₋₁₂alkenylnaphthyls,C₂₋₆alkenylphenylC₁₋₆alkyls, 0-vinylcarbamates and O-vinylcarbonates.Non-limiting examples of cationic reactive groups include vinyl ethersor epoxide groups and mixtures thereof. In one embodiment the freeradical reactive groups comprises (meth)acrylate, acryloxy,(meth)acrylamide, and mixtures thereof.

Suitable monovalent alkyl and aryl groups include unsubstitutedmonovalent C₁ to C₁₆alkyl groups, C₆-C₁₄ aryl groups, such assubstituted and unsubstituted methyl, ethyl, propyl, butyl,2-hydroxypropyl, propoxypropyl, polyethyleneoxypropyl, combinationsthereof and the like.

In one example, b is zero, one R¹ is a monovalent reactive group, and atleast 3 R¹ are selected from monovalent alkyl groups having one to 16carbon atoms, and in another example from monovalent alkyl groups havingone to 6 carbon atoms. Non-limiting examples of silicone components ofthis embodiment include2-methyl-,2-hydroxy-3-[3-[1,3,3,3-tetramethyl-1-[(trimethylsilyl)oxy]disiloxanyl]propoxy]propylester (“SiGMA”),2-hydroxy-3-methacryloxypropyloxypropyl-tris(trimethylsiloxy)silane,3-methacryloxypropyltris(trimethylsiloxy)silane (“TRIS”),3-methacryloxypropylbis(trimethylsiloxy)methylsilane and3-methacryloxypropylpentamethyl disiloxane.

In another example, b is 2 to 20, 3 to 15 or in some examples 3 to 10;at least one terminal R¹ comprises a monovalent reactive group and theremaining R¹ are selected from monovalent alkyl groups having 1 to 16carbon atoms, and in another embodiment from monovalent alkyl groupshaving 1 to 6 carbon atoms. In yet another embodiment, b is 3 to 15, oneterminal R¹ comprises a monovalent reactive group, the other terminal R¹comprises a monovalent alkyl group having 1 to 6 carbon atoms and theremaining R¹ comprise monovalent alkyl group having 1 to 3 carbon atoms.Non-limiting examples of silicone components of this embodiment include(mono-(2-hydroxy-3-methacryloxypropyl)-propyl ether terminatedpolydimethylsiloxane (400-1000 MW)) (“OH-mPDMS”), monomethacryloxypropylterminated mono-n-butyl terminated polydimethylsiloxanes (800-1000 MW),(“mPDMS”).

In another example, b is 5 to 400 or from 10 to 300, both terminal R¹comprise monovalent reactive groups and the remaining R¹ areindependently selected from monovalent alkyl groups having 1 to 18carbon atoms, which may have ether linkages between carbon atoms and mayfurther comprise halogen.

In one example, where a silicone hydrogel lens is desired, the lens ofthe present disclosure will be made from a reactive mixture comprisingat least about 20 and preferably between about 20 and 70% wt siliconecontaining components based on total weight of reactive monomercomponents from which the polymer is made.

In another embodiment, one to four R¹ comprises a vinyl carbonate orcarbamate of the formula:

wherein:

Y denotes O—, S— or NH—;

R denotes, hydrogen or methyl; d is 1, 2, 3 or 4; and q is 0 or 1.

The silicone-containing vinyl carbonate or vinyl carbamate monomersspecifically include:1,3-bis[4-(vinyloxycarbonyloxy)but-1-yl]tetramethyl-disiloxane;3-(vinyloxycarbonylthio) propyl-[tris(trimethylsiloxy)silane];3-[tris(trimethylsiloxy)silyl]propyl allyl carbamate;3-[tris(trimethylsiloxy)silyl]propyl vinyl carbamate;trimethylsilylethyl vinyl carbonate; trimethylsilylmethyl vinylcarbonate, and

Where biomedical devices with modulus below about 200 are desired, onlyone R¹ shall comprise a monovalent reactive group and no more than twoof the remaining R¹ groups will comprise monovalent siloxane groups.

Another class of silicone-containing components includes polyurethanemacromers of the following formulae:

(*D*A*D*G)_(a) *D*D*E¹;

E(*D*G*D*A)_(a) *D*G*D*E¹ or;

E(*D*A*D*G)_(a) *D*A*D*E¹  Formulae IV-VI

wherein:

D denotes an alkyl diradical, an alkyl cycloalkyl diradical, acycloalkyl diradical, an aryl diradical or an alkylaryl diradical having6 to 30 carbon atoms,

G denotes an alkyl diradical, a cycloalkyl diradical, an alkylcycloalkyl diradical, an aryl diradical or an alkylaryl diradical having1 to 40 carbon atoms and which may contain ether, thio or amine linkagesin the main chain;

* denotes a urethane or ureido linkage;

_(a) is at least 1;

A denotes a divalent polymeric radical of formula:

R¹¹ independently denotes an alkyl or fluoro-substituted alkyl grouphaving 1 to 10 carbon atoms, which may contain ether linkages betweencarbon atoms; y is at least 1; and p provides a moiety weight of 400 to10,000; each of E and E¹ independently denotes a polymerizableunsaturated organic radical represented by formula:

wherein: R¹² is hydrogen or methyl; R¹³ is hydrogen, an alkyl radicalhaving 1 to 6 carbon atoms, or a —CO—Y—R¹⁵ radical wherein Y is —O—,Y—S— or —NH—; R¹⁴ is a divalent radical having 1 to 12 carbon atoms; Xdenotes —CO— or —OCO—; Z denotes —O— or —NH—; Ar denotes an aromaticradical having 6 to 30 carbon atoms; w is 0 to 6; x is 0 or 1; y is 0 or1; and z is 0 or 1.

A preferred silicone-containing component is a polyurethane macromerrepresented by the following formula:

wherein R¹⁶ is a diradical of a diisocyanate after removal of theisocyanate group, such as the diradical of isophorone diisocyanate.Another suitable silicone containing macromer is compound of formula X(in which x+y is a number in the range of 10 to 30) formed by thereaction of fluoroether, hydroxy-terminated polydimethylsiloxane,isophorone diisocyanate and isocyanatoethylmethacrylate.

Other silicone containing components suitable for use in this inventioninclude macromers containing polysiloxane, polyalkylene ether,diisocyanate, polyfluorinated hydrocarbon, polyfluorinated ether andpolysaccharide groups; polysiloxanes with a polar fluorinated graft orside group having a hydrogen atom attached to a terminaldifluoro-substituted carbon atom; hydrophilic siloxanyl methacrylatescontaining ether and siloxanyl linkanges and crosslinkable monomerscontaining polyether and polysiloxanyl groups. Any of the foregoingpolysiloxanes may also be used as the silicone containing component inthe present disclosure.

Liquid Crystal Materials

There may be numerous materials that may have characteristics consistentwith the liquid crystal layer types that have been discussed herein. Itmay be expected that liquid crystal materials with favorable toxicitymay be preferred and naturally derived cholesteryl based liquid crystalmaterials may be useful. In other examples, the encapsulation technologyand materials of ophthalmic inserts may allow a broad choice ofmaterials that may include the LCD display related materials which maytypically be of the broad categories related to nematic or cholesteric Nor smectic liquid crystals or liquid crystal mixtures. Commerciallyavailable mixtures such as Merck Specialty chemicals Licristal mixturesfor TN, VA, PSVA, IPS and FFS applications and other commerciallyavailable mixtures may form a material choice to form a liquid crystallayer.

In a non-limiting sense, mixtures or formulations may comprise thefollowing liquid crystal materials:1-(trans-4-Hexylcyclohexyl)-4-isothiocyanatobenzene liquid crystal,benzoic acid compounds including (4-Octylbenzoic acid and 4-Hexylbenzoicacid), carbonitrile compounds including(4′-Pentyl-4-biphenylcarbonitrile, 4′-Octyl-4-biphenylcarbonitrile,4′-(Octyloxy)-4-biphenylcarbonitrile,4′-(Hexyloxy)-4-biphenylcarbonitrile,4-(trans-4-Pentylcyclohexyl)benzonitrile,4′-(Pentyloxy)-4-biphenylcarbonitrile, 4′-Hexyl-4-biphenylcarbonitrile),and 4,4′-Azoxyanisole.

In a non-limiting sense, formulations showing particularly highbirefringence of n_(par)−n_(perp)>0.3 at room temperature may be used asa liquid crystal layer forming material. For example, such formulationreferred to as W1825 may be as available from AWAT and BEAM Engineeringfor Advanced Measurements Co. (BEAMCO).

There may be other classes of liquid crystal materials that may beuseful for the inventive concepts here. For example, ferroelectricliquid crystals may provide function for electric field oriented liquidcrystal embodiments, but may also introduce other effects such asmagnetic field interactions. Interactions of electromagnetic radiationwith the materials may also differ.

Alignment Layer Materials:

In many of the examples that have been described, the liquid crystallayers within ophthalmic lenses may need to be aligned in variousmanners at insert boundaries. The alignment, for example, may beparallel or perpendicular to the boundaries of the inserts, and thisalignment may be obtained by proper processing of the various surfaces.The processing may involve coating the substrates of the inserts thatcontain the liquid crystal (LC) by alignment layers. Those alignmentlayers are described herein.

A technique commonly practiced in liquid crystal based devices ofvarious types may be the rubbing technique. This technique may beadapted to account for the curved surfaces such as the ones of theinsert pieces used for enclosing the liquid crystal. In an example, thesurfaces may be coated by a Polyvinyl Alcohol (PVA) layer. For example,a PVA layer may be spin coated using a 1 wt. % aqueous solution. Thesolution may be applied with spin coating at 1000 rpm for time such asapproximately 60 s, and then dried. Subsequently, the dried layer maythen be rubbed by a soft cloth. In a non-limiting example, the softcloth may be velvet.

Photo-alignment may be another technique for producing alignment layersupon liquid crystal enclosures. In some examples, photo-alignment may bedesirable due to its non-contact nature and the capability of largescale fabrication. In a non-limiting example, the photo-alignment layerused in the liquid crystal variable optic portion may be comprised of adichroic azobenzene dye (azo dye) capable of aligning predominantly inthe direction perpendicular to the polarization of linear polarizedlight of typically UV wavelengths. Such alignment may be a result ofrepetitive trans-cis-trans photoisomerization processes.

As an example, PAAD series azobenzene dyes may be spin coated from a 1wt. % solution in DMF at 3000 rpm for 30 s. Subsequently, the obtainedlayer may be exposed to a linear polarized light beam of a UV wavelength(such as for example, 325 nm, 351 nm, 365 nm) or even a visiblewavelength (400-500 nm). The source of the light may take various forms.In some embodiments, light may originate from laser sources for example.Other light sources such as LEDs, halogen and incandescent sources maybe other non-limiting examples. Either before or after the various formsof light are polarized in the various patterns as appropriate, the lightmay be collimated in various manners such as through the use of opticallensing devices. Light from a laser source may inherently have a degreeof collimation, for example.

A large variety of photoanisotropic materials are known currently, basedon azobenzene polymers, polyesthers, photo-crosslinkable polymer liquidcrystals with mesogenic 4-(4-methoxycinnamoyloxy)biphenyl side groupsand the like. Examples of such materials include sulfonic bisazodye SD1and other azobenzene dyes, particularly, PAAD-series materials availablefrom BEAM Engineering for Advanced Measurements Co. (BEAMCO), Poly(vinylcinnamates), and others.

In some examples, it may be desirable to use water or alcohol solutionsof PAAD series azo dyes. Some azobenzene dyes, for example, Methyl Red,may be used for photoalignment by directly doping a liquid crystallayer. Exposure of the azobenzene dye to a polarized light may causediffusion and adhesion of the azo dyes to and within the bulk of theliquid crystal layer to the boundary layers creating desired alignmentconditions.

Azobenzene dyes such as Methyl Red may also be used in combination witha polymer, for example, PVA. Other photoanisotropic materials capable ofenforcing alignment of adjacent layers of liquid crystals may beacceptable are known currently. These examples may include materialsbased on coumarines, polyesthers, photo-crosslinkable polymer liquidcrystals with mesogenic 4-(4-methoxycinnamoyloxy)-biphenyl side groups,poly(vinyl cinnamates), and others. The photo-alignment technology maybe advantageous for embodiments comprising patterned orientation ofliquid crystal.

In another example of producing alignment layers, the alignment layermay be obtained by vacuum deposition of silicon oxide (SiOx where1<=X<=2) on the insert piece substrates. For example, SiO₂ may bedeposited at low pressure such as ˜10⁻⁶ mbar. It may be possible toprovide alignment features at a nanoscaled size that are injectionmolded into with the creation of the front and back insert pieces. Thesemolded features may be coated in various manners with the materials thathave been mentioned or other materials that may directly interact withphysical alignment features and transmit the alignment patterning intoalignment orientation of liquid crystal molecules.

Ion-beam alignment may be another technique for producing alignmentlayers upon liquid crystal enclosures. In some examples, a collimatedargon ion or focused gallium ion beam may be bombarded upon thealignment layer at a defined angle/orientation. This type of alignmentmay also be used to align silicon oxide, diamond-like-carbon (DLC),polyimide and other alignment materials.

Still further examples may relate to the creation of physical alignmentfeatures to the insert pieces after they are formed. Rubbing techniquesas are common in other Liquid Crystal based art may be performed uponthe molded surfaces to create physical grooves. The surfaces may also besubjected to a post-molding embossing process to create small groovedfeatures upon them. Still further embodiments may derive from the use ofetching techniques which may involve optical patterning processes ofvarious kinds

Dielectric Materials

Dielectric films and dielectrics are described herein. By way ofnon-limiting examples, the dielectric film or dielectrics used in theliquid crystal variable optic portion possess characteristicsappropriate to the invention described herein. A dielectric may compriseone or more material layers functioning alone or together as adielectric. Multiple layers may be used to achieve dielectricperformance superior to that of a single dielectric.

The dielectric may permit a defect-free insulating layer at a thicknessdesired for the discretely variable optic portion, for example, between1 and 10 μm. A defect may be referred to as a pinhole, as is known bythose skilled in the art to be a hole in the dielectric permittingelectrical and/or chemical contact through the dielectric. Thedielectric, at a given thickness, may meet requirements for breakdownvoltage, for example, that the dielectric should withstand 100 volts ormore.

The dielectric may allow for fabrication onto curved, conical,spherical, and complex three-dimensional surfaces (e.g., curved surfacesor non-planar surfaces). Typical methods of dip- and spin-coating may beused, or other methods may be employed.

The dielectric may resist damage from chemicals in the variable opticportion, for example the liquid crystal or liquid crystal mixture,solvents, acids, and bases or other materials that may be present in theformation of the liquid crystal region. The dielectric may resist damagefrom infrared, ultraviolet, and visible light. Undesirable damage mayinclude degradation to parameters described herein, for example,breakdown voltage and optical transmission. The dielectric may resistpermeation of ions. The dielectric may prevent electromigration,dendrite growth, and other degradations of the underlying electrodes.The dielectric may adhere to an underlying electrode and/or substrate,for example, with the use of an adhesion promotion layer. The dielectricmay be fabricated using a process which allows for low contamination,low surface defects, conformal coating, and low surface roughness.

The dielectric may possess relative permittivity or a dielectricconstant which is compatible with electrical operation of the system,for example, a low relative permittivity to reduce capacitance for agiven electrode area. The dielectric may possess high resistivity,thereby permitting a very small current to flow even with high appliedvoltage. The dielectric may possess qualities desired for an opticdevice, for example, high transmission, low dispersion, and refractiveindex within a certain range.

Example, non-limiting, dielectric materials, include one or more ofParylene-C, Parylene-HT, Silicon Dioxide, Silicon Nitride, and TeflonAF.

Electrode Materials

Electrodes are described herein for applying an electric potential forachieving an electric field across the liquid crystal region. Anelectrode generally comprises one or more material layers functioningalone or together as an electrode.

The electrode may adhere to an underlying substrate, dielectric coating,or other objects in the system, perhaps with the use of an adhesionpromoter (e.g., methacryloxypropyltrimethoxysilane). The electrode mayform a beneficial native oxide or be processed to create a beneficialoxide layer. The electrode may be transparent, substantially transparentor opaque, with high optical transmission and little reflection. Theelectrode may be patterned or etched with known processing methods. Forexample, the electrodes may be evaporated, sputtered, or electroplated,using photolithographic patterning and/or lift-off processes.

The electrode may be designed to have suitable resistivity for use inthe electrical system described herein, for example, meeting therequirements for resistance in a given geometric construct.

The electrodes may be manufactured from one or more of indium tin oxide(ITO), aluminum-doped zinc oxide (AZO), gold, stainless steel, chrome,graphene, graphene-doped layers and aluminum. It will be appreciatedthat this is not an exhaustive list.

The electrodes may be used to establish an electric field in a regionbetween the electrodes. In some embodiments, there may be numeroussurfaces upon which electrodes may be formed. It may be possible toplace electrodes on any or all of the surfaces that are defined, and anelectric field may be established in the region between any of thesurfaces upon which electrodes have been formed by application ofelectric potential to at least those two surfaces.

Processes

The following method steps are provided as examples of processes thatmay be implemented according to some aspects of the present disclosure.It should be understood that the order in which the method steps arepresented is not meant to be limiting and other orders may be used toimplement the invention. In addition, not all of the steps are requiredto implement the present disclosure and additional steps may be includedin various embodiments of the present disclosure. It may be obvious toone skilled in the art that additional embodiments may be practical, andsuch methods are well within the scope of the claims.

Referring to FIG. 7, a flowchart illustrates exemplary steps that may beused to implement the present disclosure. At 701, forming a firstsubstrate layer which may comprise a back curve surface and have a topsurface with a shape of a first type that may differ from the shape ofsurface of other substrate layers. In some examples, the difference mayinclude a different radius of curvature of the surface at least in aportion that may reside in the optical zone. At 702, forming a secondsubstrate layer which may comprise a front curve surface or anintermediate surface or a portion of an intermediate surface for morecomplicated devices. At 703, an electrode layer may be deposited uponthe first substrate layer. The deposition may occur, for example, byvapor deposition or electroplating. In some embodiments, the firstsubstrate layer may be part of an insert that has regions both in theoptical zone and regions in the non-optic zone. The electrode depositionprocess may simultaneously define interconnect features in someembodiments. In some examples a dielectric layer may be formed upon theinterconnects or electrodes. The dielectric layer may comprise numerousinsulating and dielectric layers such as for example silicon dioxide.

At 704, the first substrate layer may be further processed to add analignment layer upon the previously deposited dielectric or electrodelayer. The alignment layers may be deposited upon the top layer on thesubstrate and then processed in standard manners, for example, rubbingtechniques, to create the grooving features that are characteristic ofstandard alignment layers or by treatment with exposure to energeticparticles or light. Thin layers of photoanisotropic materials may beprocessed with light exposure to form alignment layers with variouscharacteristics. As mentioned previously, in methods to form layers ofliquid crystal wherein polymer networked regions of interstitiallylocated liquid crystal are formed, the methods may not include stepsrelated to the formation of alignment layers.

At 705, the second substrate layer may be further processed. Anelectrode layer may be deposited upon the second substrate layer in ananalogous fashion to step 703. Then in some examples, at 706, adielectric layer may be applied upon the second substrate layer upon theelectrode layer. The dielectric layer may be formed to have a variablethickness across its surface. As an example, the dielectric layer may bemolded upon the first substrate layer. Alternatively, a previouslyformed dielectric layer may be adhered upon the electrode surface of thesecond substrate piece.

At 707, an alignment layer may be formed upon the second substrate layerin similar fashion to the processing step at 704. After 707, twoseparate substrate layers that may form at least a portion of anophthalmic lens insert may be ready to be joined. In some examples at708, the two pieces will be brought in close proximity to each other andthen liquid crystal material may be filled in between the pieces. Theremay be numerous manners to fill the liquid crystal in between the piecesincluding as non-limiting examples, vacuum based filling where thecavity is evacuated and liquid crystal material is subsequently allowedto flow into the evacuated space. In addition, the capillary forces thatare present in the space between the lens insert pieces may aid in thefilling of the space with liquid crystal material. At 709, the twopieces may be brought adjacent to each other and then sealed to form avariable optic element with liquid crystal. There may be numerousmanners of sealing the pieces together including the use of adhesives,sealants, and physical sealing components such as o-rings and snap lockfeatures as non-limiting examples.

In some examples, two pieces of the type formed at 709 may be created byrepeating method steps 701 to 709 wherein the alignment layers areoffset from each other to allow for a lens that may adjust the focalpower of non-polarized light. In such examples, the two variable opticlayers may be combined to form a single variable optic insert. At 710,the variable optic portion may be connected to the energy source andintermediate or attached components may be placed thereon.

At 711, the variable optic insert resulting at step 710 may be placedwithin a mold part. The variable optic insert may or may not alsocomprise one or more components. In some preferred embodiments, thevariable optic insert is placed in the mold part via mechanicalplacement. Mechanical placement may include, for example, a robot orother automation, such as that known in the industry to placesurface-mount components. Human placement of a variable optic insert isalso within the scope of the present disclosure. Accordingly, anymechanical placement or automation may be utilized which is effective toplace a variable optic insert with an energy source within a cast moldpart such that the polymerization of a reactive mixture contained by themold part will include the variable optic in a resultant ophthalmiclens.

In some examples, a variable optic insert may be placed in a mold partattached to a substrate. An energy source and one or more components mayalso be attached to the substrate and may be in electrical communicationwith the variable optic insert. Components may include for example,circuitry to control power applied to the variable optic insert.Accordingly, in some examples a component includes control mechanism foractuating the variable optic insert to change one or more opticalcharacteristics, such as, for example, a change of state between a firstoptical power and a second optical power.

In some examples, a processor device, microelectromechanical system(MEMS), nanoelectromechanical system (NEMS) or other component may alsobe placed into the variable optic insert and in electrical contact withthe energy source. At 712, a reactive monomer mixture may be depositedinto a mold part. At 713, the variable optic insert may be positionedinto contact with the reactive mixture. In some examples the order ofplacement of variable optic and depositing of monomer mixture may bereversed. At 714, the first mold part is placed proximate to a secondmold part to form a lens-forming cavity with at least some of thereactive monomer mixture and the variable optic insert in the cavity. Asdiscussed above, preferred embodiments include an energy source and oneor more components also within the cavity and in electricalcommunication with the variable optic insert.

At 715, the reactive monomer mixture within the cavity is polymerized.Polymerization may be accomplished, for example, via exposure to one orboth of actinic radiation and heat. At 716, the ophthalmic lens isremoved from the mold parts with the variable optic insert adhered to orencapsulated within the insert-encapsulating polymerized material makingup the ophthalmic lens.

Although the invention herein may be used to provide hard or softcontact lenses made of any known lens material, or material suitable formanufacturing such lenses, preferably, the lenses of the invention aresoft contact lenses having water contents of about 0 to about 90percent. More preferably, the lenses are made of monomers containinghydroxy groups, carboxyl groups, or both or be made fromsilicone-containing polymers, such as siloxanes, hydrogels, siliconehydrogels, and combinations thereof. Material useful for forming thelenses of the invention may be made by reacting blends of macromers,monomers, and combinations thereof along with additives such aspolymerization initiators. Suitable materials include, withoutlimitation, silicone hydrogels made from silicone macromers andhydrophilic monomers.

Apparatus

Referring now to FIG. 8, automated apparatus 810 is illustrated with oneor more transfer interfaces 811. Multiple mold parts, each with anassociated variable optic insert 814 are contained on a pallet 813 andpresented to transfer interfaces 811. Examples, may include, for examplea single interface individually placing variable optic insert 814, ormultiple interfaces (not shown) simultaneously placing variable opticinserts 814 into the multiple mold parts, and in some examples, in eachmold part. Placement may occur via vertical movement 815 of the transferinterfaces 811.

Another aspect of some examples of the present disclosure includesapparatus to support the variable optic insert 814 while the body of theophthalmic lens is molded around these components. In some examples thevariable optic insert 814 and an energy source may be affixed to holdingpoints in a lens mold (not illustrated). The holding points may beaffixed with polymerized material of the same type that will be formedinto the lens body. Other examples include a layer of prepolymer withinthe mold part onto which the variable optic insert 814 and an energysource may be affixed.

Processors Included in Insert Devices

Referring now to FIG. 9, a controller 900 is illustrated that may beused in some examples of the present disclosure. The controller 900includes a processor 910, which may include one or more processorcomponents coupled to a communication device 920. In some examples, acontroller 900 may be used to transmit energy to the energy sourceplaced in the ophthalmic lens.

The controller may include one or more processors, coupled to acommunication device configured to communicate energy via acommunication channel. The communication device may be used toelectronically control one or more of the placement of a variable opticinsert into the ophthalmic lens or the transfer of a command to operatea variable optic device.

The communication device 920 may also be used to communicate, forexample, with one or more controller apparatus or manufacturingequipment components.

The processor 910 is also in communication with a storage device 930.The storage device 930 may comprise any appropriate information storagedevice, including combinations of magnetic storage devices (e.g.,magnetic tape and hard disk drives), optical storage devices, and/orsemiconductor memory devices such as Random Access Memory (RAM) devicesand Read Only Memory (ROM) devices.

The storage device 930 may store a program 940 for controlling theprocessor 910. The processor 910 performs instructions of the program940, and thereby operates in accordance with the present disclosure. Forexample, the processor 910 may receive information descriptive ofvariable optic insert placement, processing device placement, and thelike. The storage device 930 may also store ophthalmic related data inone or more databases 950, 960. The database 950 and 960 may includespecific control logic for controlling energy to and from a variableoptic lens.

A Variable Optic Insert Including Gradient Indexed Liquid CrystalElements and Dielectric Layers

Referring to FIG. 10A, a variable optic portion 1000 that may beinserted into an ophthalmic lens is illustrated with a liquid crystallayer 1025. The variable optic portion 1000 may have a similar diversityof materials and structural relevance as has been discussed in othersections of this specification. In some examples, a first transparentelectrode 1050 may be placed on a first transparent substrate 1055. Thefirst lens piece may include a dielectric layer 1040. The layer may becomprised of a dielectric film, and in some examples, alignment layersmay be placed upon the dielectric layer 1040. In other examples thedielectric layers may be formed in such manners to have a dual functionof an alignment layer. In examples comprising dielectric layers, theshape of the dielectric layer 1040 of the first lens surface may form aregionally varied dielectric thickness as depicted. Such a regionallyvaried shape may introduce additional focusing power of the lens elementabove geometric effects of curved layers. In some examples, for example,the shaped dielectric layer may be formed by injection molding upon thefirst transparent electrode 1050 first transparent substrate 1055combination.

In some examples the first transparent electrode 1050 and a secondtransparent electrode 1015 may be shaped in various manners. In someexamples, the shaping may result in separate distinct regions beingformed that may have energization applied separately. In other examples,the electrodes may be formed into patterns such as a helix from thecenter of the lens to the periphery which may apply a variable electricfield across the liquid crystal layer 1025. In either case, suchelectrode shaping may be performed in addition to the shaping ofdielectric layer upon the electrode or instead of such shaping. Theshaping of electrodes in these manners may also introduce additionalfocusing power of the lens element under operation.

The liquid crystal layer 1025 may be located between the firsttransparent electrode 1050 and a second transparent electrode 1015. Thesecond transparent electrode 1015 may be attached to a secondtransparent substrate layer 1010, wherein the device formed from thesecond transparent substrate layer 1010 to the first transparentsubstrate 1055 may contain the variable optic portion of the ophthalmiclens. Two alignment layers may also be located at 1020 and 1030 upon thedielectric layer and may surround the liquid crystal layer 1025. Thealignment layers at 1020 and 1030 may function to define a restingorientation of the ophthalmic lens. In some examples, the electrodelayers may be in electrical communication with liquid crystal layer 1025and cause a shift in orientation from the resting orientation to atleast one energized orientation.

Referring to FIG. 10B, an alternative of a variable optic portion 1056which may be inserted into an ophthalmic lens is illustrated with agradient indexed liquid crystal layer 1075. Similar to variable opticportion 1000 in FIG. 10A, there may be layers of shaped dielectricswithin the insert. For example, layers including 1085, 1090 and 1095 mayform a composite shaped dielectric layer upon an exemplary first lenspiece 1097. The electrical effect of the dielectric layer may shape theeffective electric field that is applied across the liquid crystal layer1075 when the insert is energized. A first transparent electrode 1096may be located on a first substrate layer or lens piece 1097 and asecond transparent electrode 1065 on a second substrate layer which hasbeen referred to as the second substrate layer 1060. In some examples,alignment layers may also be located around the liquid crystal layer1075 and influence the alignment of molecules therein.

The insert (which may also be called variable optic portion 1056) may bedepicted with multiple dielectric layers at 1085, 1090 and 1095. In someembodiments one type of dielectric material may comprise mediandielectric layer 1085 and median dielectric layer 1095 while a differenttype of material may comprise layer 1090. In some examples, such arelatively complex structure may allow for the combination of dielectricmaterials that have a different effective dielectric strength atdifferent frequencies. For example, median dielectric layers 1085 and1095 may be comprised of silicon dioxide in a non-limiting sense whilethe material at layer 1090 may be an aqueous solution. At opticalfrequencies these layers may be formed in such a manner that the effecton a light beam may be similar for all layers. Yet, at lower electricalfrequencies as may be applied to the electrodes 1065 and 1096 an aqueousform of the layer 1090 may have a different dielectric property than theother layers allowing for enhanced effects on the regional shaping ofthe dielectric field that may be operant across the liquid crystal layer1075.

The variable optic portion 1056 may include a median dielectric layer1085 that may form a surface layer upon which the liquid crystal layer1075 may be deposited. In some embodiments, the median dielectric layer1085 may also act to contain the second lens element if said second lenselement is in liquid form. Some embodiments may include a liquid crystallayer 1075 located between a first alignment layer 1080 and a secondalignment layer 1070 wherein the second alignment layer 1070 is placedupon a second transparent electrode 1065. A top substrate layer 1060 maycontain the combination of layers that form the variable optic portion1056, which may respond to electrical fields applied across itselectrodes 1065 and 1096. The alignment layers may affect the opticalcharacteristics of the variable optic portion 1056 by various means.

The ability to vary the dielectric thickness across the surface of theelectrode may allow for the effective programing of a varied dielectricfield from the center of the lens to the edge. In some examples as havebeen described, a gradient indexed pattern in the liquid crystal layersmay be the default focusing condition of a variable optic portionwithout any electrical bias. As has been described, in these examples itis possible to apply a large enough voltage to the electrodes such thatthe field causes all liquid crystal to align completely with theelectric field, effectively erasing the gradient indexed pattern. It maybe possible to shape the thickness of the liquid crystal layer such thatthe field across the liquid crystal layer when a single voltagepotential is applied to electrodes is still consistent with a focusinggradient indexed pattern. Alternatively, by shaping the dielectriclayers as has been discussed, in some examples it may be possible thatthe resulting electric field that results across a liquid crystal layerrelative to a location across the optic zone of an ophthalmic device maybe consistent with at least a second focal condition of the device. Insuch manners, the ophthalmic device may have additional operationalstates than the initial programmed gradient indexed pattern and a statewhere the pattern has been removed.

In this description, reference has been made to elements illustrated inthe figures. Many of the elements are depicted for reference to depictthe embodiments of the inventive art for understanding. The relativescale of actual features may be significantly different from that asdepicted, and variation from the depicted relative scales should beassumed within the spirit of the art herein. For example, liquid crystalmolecules may be of a scale to be impossibly small to depict against thescale of insert pieces. The depiction of features that represent liquidcrystal molecules at a similar scale to insert pieces to allow forrepresentation of factors such as the alignment of the molecules istherefore such an example of a depicted scale that in actual embodimentsmay assume much different relative scale.

Although shown and described in what is believed to be the mostpractical and preferred embodiments, it is apparent that departures fromspecific designs and methods described and shown will suggest themselvesto those skilled in the art and may be used without departing from thespirit and scope of the invention. The present disclosure is notrestricted to the particular constructions described and illustrated,but should be constructed to cohere with all modifications that may fallwithin the scope of the appended claims.

1. An ophthalmic lens device with a variable optic insert positionedwithin at least a portion of an optical zone of the ophthalmic lensdevice, wherein the variable optic insert comprises: a curved frontsurface and a curved back surface, wherein the front surface and theback surface are configured to bound at least a portion of one chamber;a dielectric layer proximate to at least one of the curved front surfaceand the curved back surface, wherein a thickness of the dielectric layervaries at least within the portion within the optical zone; an energysource embedded in the variable optic insert in at least a regioncomprising a non-optical zone; and a layer containing liquid crystalmaterial positioned within the at least one chamber, wherein the layerincludes regions of liquid crystal material aligned in a pattern whereinan index of refraction across at least a first portion of the variableoptic insert varies with a radial dependence.
 2. The ophthalmic lensdevice of claim 1 wherein the index of refraction across at least thefirst portion of the optic insert has a parabolic dependence on a radialdimension.
 3. The ophthalmic lens device of claim 2 wherein an opticaleffect of the layer containing liquid crystal material is supplementedby an effect of the thickness of the dielectric layer when an electricfield is applied across the layer containing liquid crystal material. 4.The ophthalmic lens device of claim 3 wherein the lens is a contactlens.
 5. The ophthalmic lens device of claim 4 further comprising: afirst layer of electrode material proximate to the curved back surface;and a second layer of electrode material proximate to the curved frontsurface.
 6. The ophthalmic lens device of claim 5 wherein at least aportion of the layer containing liquid crystal material varies its indexof refraction affecting a ray of light traversing the layer containingliquid crystal material when an electric potential is applied across thefirst layer of electrode material and the second layer of electrodematerial.
 7. The ophthalmic lens device of claim 6 wherein the variableoptic insert alters a focal characteristic of the lens.
 8. Theophthalmic lens device of claim 7 further comprising an electricalcircuit, wherein the electrical circuit controls a flow of electricalenergy from the energy source to the first and second electrode layers.9. The ophthalmic lens device of claim 8 wherein the electrical circuitcomprises a processor.
 10. An ophthalmic lens device with a variableoptic insert positioned within at least a portion of an optical zone ofthe ophthalmic lens device, wherein the variable optic insert comprises:a curved first front surface and a curved first back surface wherein thefirst front surface and the first back surface are configured to boundat least a portion of a first chamber; a curved second front surface anda curved second back surface wherein the second front surface and thesecond back surface are configured to bound at least a portion of asecond chamber; a dielectric layer proximate to at least one of thecurved first front surface and the curved first back surface, wherein athickness of the dielectric layer varies at least within the portionwithin the optical zone; at least one layer containing liquid crystalmaterial positioned within the at least one chamber, wherein the atleast one layer includes regions of liquid crystal material aligned in apattern wherein an index of refraction across at least a first portionof the variable optic insert varies with a radial dependence; and anenergy source embedded in the insert in at least a region comprising anon-optical zone.
 11. The ophthalmic lens device of claim 10 wherein theindex of refraction across at least the first portion of the opticinsert has a parabolic dependence on a radial dimension.
 12. Theophthalmic lens device of claim 11 wherein an optical effect of thelayer containing liquid crystal material is supplemented by an effect ofthe thickness of the dielectric layer when an electric field is appliedacross the layer containing liquid crystal material.
 13. The ophthalmiclens device of claim 10 wherein the lens is a contact lens.
 14. Theophthalmic lens device of claim 13 further comprising: a first layer ofelectrode material proximate to the first curved back surface; and asecond layer of electrode material proximate to the curved first frontsurface.
 15. The ophthalmic lens device of claim 14 wherein the layercontaining liquid crystal material varies its index of refractionaffecting a ray of light traversing the layer containing liquid crystalmaterial when an electric potential is applied across the first layer ofelectrode material and the second layer of electrode material.
 16. Theophthalmic lens device of claim 15 wherein the variable optic insertalters a focal characteristic of the lens.
 17. The ophthalmic lensdevice of claim 16 further comprising an electrical circuit, wherein theelectrical circuit controls a flow of electrical energy from the energysource to the first and second electrode layers.
 18. The ophthalmic lensdevice of claim 17 wherein the electrical circuit comprises a processor.19. A contact lens device with a variable optic insert positioned withinat least a portion of an optical zone of the contact lens device,wherein the variable optic insert comprises: a curved first frontsurface and a curved first back surface wherein the first front surfaceand the first back surface are configured to form at least a firstchamber; a first layer of electrode material proximate to the curvedfirst front surface; a second layer of electrode material proximate tothe curved first back surface; a dielectric layer proximate to at leastone of the curved first front surface and the curved first back surface,wherein the dielectric layer varies in thickness at least within theportion within the optical zone; a first layer containing liquid crystalmaterial positioned within the first chamber, wherein the first layerincludes regions of liquid crystal material aligned in a first patternwherein a first index of refraction across at least a first portion ofthe variable optic insert varies with a first radial dependence, andwherein the first layer containing liquid crystal material varies itsfirst index of refraction affecting a first ray of light traversing thefirst layer containing liquid crystal material when a first electricpotential is applied across the first layer of electrode material andthe second layer of electrode material; a curved second front surfaceand a curved second back surface wherein the second front surface andthe second back surface are configured to form at least a secondchamber; a third layer of electrode material proximate to the curvedsecond front surface; a fourth layer of electrode material proximate tothe curved second back surface; a second layer containing liquid crystalmaterial positioned within the second chamber, wherein the second layerincludes regions of liquid crystal material aligned in a second patternwherein a second index of refraction across at least a second portion ofthe variable optic insert varies with a second radial dependence, andwherein the second layer containing liquid crystal material varies itssecond index of refraction affecting a second ray of light traversingthe second layer containing liquid crystal material when a secondelectric potential is applied across the third layer of electrodematerial and the fourth layer of electrode material; an energy sourceembedded in the insert in at least a region comprising a non-opticalzone; and an electrical circuit comprising a processor, wherein theelectrical circuit controls a flow of electrical energy from the energysource to one or more of the first, second, third or fourth electrodelayers; and wherein the variable optic insert alters a focalcharacteristic of the contact lens device.
 20. A contact lens devicewith a variable optic insert positioned within at least a portion of anoptical zone of the contact lens device, wherein the variable opticinsert comprises: a layer containing liquid crystal material positionedwithin the variable optic insert, wherein the layer includes regions ofliquid crystal material aligned in a pattern wherein an index ofrefraction across at least a first portion of the variable optic insertvaries with a radial dependence; a dielectric layer proximate to thelayer containing liquid crystal material, wherein the dielectric layervaries in thickness at least within the portion within the optical zone;and wherein at least a first surface of the layer containing liquidcrystal material is curved.
 21. An ophthalmic lens device with avariable optic insert positioned within at least a portion of an opticalzone of the ophthalmic lens device, wherein the variable optic insertcomprises: an insert front curve piece and an insert back curve piece,wherein a back surface of the front curve piece has a first curvatureand a front surface of the back curve piece has a second curvature; adielectric layer proximate to at least one of the front curve piece andthe back curve piece, wherein a thickness of the dielectric layer variesat least within the portion within the optical zone; an energy sourceembedded in the insert in at least a region comprising a non-opticalzone; and a layer containing liquid crystal material, wherein the layerincludes regions of liquid crystal material aligned in a pattern whereinan index of refraction across at least a first portion of the variableoptic insert varies with a radial dependence.
 22. The ophthalmic lensdevice of claim 21 wherein the index of refraction across at least thefirst portion of the optic insert has a parabolic dependence on a radialdimension.
 23. The ophthalmic lens device of claim 22 wherein an opticaleffect of the layer containing liquid crystal material is supplementedby an effect of the thickness of the dielectric layer when an electricfield is applied across the layer containing liquid crystal material.24. The ophthalmic lens device of claim 23 wherein the first curvatureis different from the second curvature.
 25. The ophthalmic lens deviceof claim 24 wherein the lens is a contact lens.
 26. The ophthalmic lensdevice of claim 25 further comprising: a first layer of electrodematerial proximate to the back surface of the front curve piece; and asecond layer of electrode material proximate to the front surface of theback curve piece.
 27. The ophthalmic lens device of claim 26 wherein thelayer containing liquid crystal material varies its index of refractionaffecting a ray of light traversing the layer containing liquid crystalmaterial when an electric potential is applied across the first layer ofelectrode material and the second layer of electrode material.
 28. Theophthalmic lens device of claim 27 wherein the variable optic insertalters a focal characteristic of the lens.
 29. The ophthalmic lensdevice of claim 28 further comprising an electrical circuit, wherein theelectrical circuit controls a flow of electrical energy from the energysource to the first and second electrode layers.
 30. The ophthalmic lensdevice of claim 29 wherein the electrical circuit comprises a processor.31. An ophthalmic lens device with a variable optic insert positionedwithin at least a portion of an optical zone of the ophthalmic lensdevice, wherein the variable optic insert comprises: an insert frontcurve piece, at least a first intermediate curve piece and an insertback curve piece, wherein a back surface of the front curve piece has afirst curvature and a front surface of the first intermediate curvepiece has a second curvature; a dielectric layer proximate to at leastone of the front curve piece and the intermediate curve piece, whereinthe dielectric layer varies in thickness at least within the portionwithin the optical zone; an energy source embedded in the insert in atleast a region comprising a non-optical zone; and the variable opticinsert comprising a layer containing liquid crystal material, whereinthe layer includes regions of liquid crystal material aligned in apattern wherein an index of refraction across at least a first portionof the variable optic insert varies with a radial dependence.
 32. Theophthalmic lens device of claim 31 wherein the index of refractionacross at least the first portion of the optic insert has a parabolicdependence on a radial dimension.
 33. The ophthalmic lens device ofclaim 32 wherein the first curvature is different from the secondcurvature.
 34. The ophthalmic lens device of claim 31 wherein the lensis a contact lens.
 35. The ophthalmic lens device of claim 34 furthercomprising: a first layer of electrode material proximate to the frontcurve piece; and a second layer of electrode material proximate to oneor more of the intermediate curve piece and the back curve piece. 36.The ophthalmic lens device of claim 34 further comprising: a first layerof electrode material proximate to the front curve piece; and a secondlayer of electrode material proximate to the intermediate curve piece.37. The ophthalmic lens device of claim 36 wherein the layer containingliquid crystal material varies its index of refraction affecting a rayof light traversing the layer containing liquid crystal material when anelectric potential is applied across the first layer of electrodematerial and the second layer of electrode material.
 38. The ophthalmiclens device of claim 37 wherein the variable optic insert alters a focalcharacteristic of the lens.
 39. The ophthalmic lens device of claim 38further comprising an electrical circuit, wherein the electrical circuitcontrols a flow of electrical energy from the energy source to the firstand second electrode layers.
 40. The ophthalmic lens device of claim 39wherein the electrical circuit comprises a processor.